Straightening machine with a modular interchangeable casette system

ABSTRACT

A straightening machine having an allocated straightening roll drive including a top bearing frame and a bottom bearing frame, in which a plurality of straightening rolls and supporting rolls are held in a cassette-like manner and arranged in an interchangeable manner. An improved adaptability of a straightening machine to different straightening requirements and straightening areas is achieved in that all the straightening rolls and supporting roils respectively arranged in the top and/or bottom bearing frame are distributed into several straightening roll segments that are modularly adapted to one another and each configured in the form of an interchangeable cassette. Each straightening roll segment includes at least one layer of supporting rolls and at least one allocated straightening roll.

The invention focuses on a straightening machine having an associatedstraightening roll drive, including an upper bearing frame and a lowerbearing frame, in which a plurality of straightening rolls andsupporting rollers are held in a cassette-like manner and are arrangedso as to be replaceable.

When processing flat material, such as flat steel or flat materialproduced from non-ferrous metal, the necessary production steps usuallyalso include the straightening process in order to produce level plane(steel) bands or plates that are free of residual stress. During thestraightening process, the respective material is bent repeatedly instraightening machines, with or without tension, by means ofstraightening rolls in order to produce the desired straighteningeffect. When straightening flat products, the respective product isusually guided through between a group of upper and lower straighteningrollers and, at the same time, is deformed plastically as a result of acorresponding setting of the upper and lower straightening rollers. Inorder to achieve the plastics deformation required in each case in thisconnection, there is a need for a bending radius which is or can bevarious depending on the band thickness or plate thickness and yieldstrength of the product to be straightened and which is realized in eachcase by means of suitable roller diameters, roller divisions and rollerpenetration depths. The possible plastic deformation of the product orof the material is all the greater, in this connection, the smaller theroller diameter. However, arbitrarily small rollers cannot be used in astraightening machine as, on the one hand, the bending forces arising,where applicable, cannot be absorbed and, on the other hand, therequired process moments for representing the shaping work, whereapplicable, cannot be made available by means of the small straighteningrollers on account of the mechanical stress being too great. This is thereason why, in the case of a given roller diameter, a given rollerdivision, being the distance between centers of two adjacent rollers,and a given penetration depth and given or desired plastic deformation,in each case only one defined product spectrum or material spectrum,which depends on the respective product thickness and the yield strengththereof, is able to be straightened. The use of straightening machineswith interchangeable cassettes and different roller diameters isdisclosed in the prior art in order, then, to configure straighteningmachines here in a relatively flexible manner and so as to be adaptableto different products.

Such a generic straightening machine is disclosed in EP 1 584 384 B1.Said document discloses a straightening machine which includes amotor-fitted drive unit and a main transmission which is drivinglyconnected thereto, wherein all the interchangeable cassettes, which arereplaceable one for another, are connectable in each case to the maintransmission, which interchangeable cassettes each comprisestraightening rollers with a variously sized diameter and a differentnumber of straightening rollers. In addition, the replaceableinterchangeable cassette with straightening rollers, which comprise asmall straightening roller diameter, comprises a single intermediatetransmission which is integrated in the interchangeable cassette and iscouplable to the main transmission of the straightening machine.Interchangeable cassettes, which are each fitted with a fixedlypredetermined tool set, which consists of straightening and supportingroller combinations, are used in this connection. All the straighteningrolls and supporting rollers which are present on an upper bearing frameor a lower bearing frame are replaced in each case. In this respect, itis known from the prior art to replace each complete set ofstraightening rolls and supporting rollers by means of aninterchangeable cassette.

An alternative to replacing a complete set by means of aninterchangeable cassette is described in WO 2008/145355 A1. Saiddocument discloses the replacement in each case of individualstraightening rolls of a straightening machine. Where required, upperand lower pairs are able to be replaced together.

In addition, the metal sheet producers are nowadays faced with therequirement that a large spectrum of metal sheets or bands of the mostvaried dimensions and strengths have to be produced in small as well asin large batch sizes. This results in the straightening machinesrequired for this having to cover a large straightening range. In orderto be able to cover a large straightening range, variously sizedstraightening roll diameters and/or variously sized divisions have to beused in the straightening machines in order to obtain optimumstraightening results. This can be achieved, in principle, with theinterchangeable cassette straightening machines, as are described, forexample, in EP 1 584 384 A1, which are fitted in each case with fixedlypredetermined tool sets, i.e. with fixedly predetermined combinations ofstraightening rolls and supporting rollers, however without theflexibility appropriate to today's production conditions. However, inorder to be able to straighten a large spectrum of dimensions andstrengths with one straightening machine, a plurality of differentinterchangeable cassette sets have to be held on standby. Whereapplicable, even multiple straightening machines have to be provided inorder to be able to adapt the requirements in an optimum manner to aproduct to be straightened in each case, i.e. to thin, middling or eventhick metal sheets.

Consequently, there is a need additionally to expand existingstraightening machines with reference to the straightening range whichis realizable therewith, i.e. the product dimensions to be processedtherewith, and in particular also to enable a cost-efficient and rapidmachine retrofit.

The object underlying the invention, consequently, is to create asolution which provides improved adaptability of a straightening machineto different straightening requirements and straightening ranges.

In the case of a straightening machine of the type designated in moredetail in the introduction, said object is achieved according to theinvention in that all the straightening rolls and supporting rollers,which are arranged respectively in the upper and/or lower bearing frame,are divided into multiple straightening roll segments, which arecoordinated with one another in a modular manner and are realized ineach case in the manner of a replaceable interchangeable cassette,wherein each straightening roll segment includes at least one layer ofsupporting rollers and at least one associated straightening roll.

Advantageous further developments and expedient configurations of theinvention are the object of the subclaims.

The invention therefore proposes providing a modular straightening tool(modular straightening roll segment) inside a lower and/or uppercassette or a lower and/or upper bearing frame in order to ensurecost-efficient and rapid machine retrofitting for expanding or adaptingthe straightening range of the straightening machine. In thisconnection, the respective modular straightening tool or the respectivetool module consists of a modular segment which is realized in themanner of a replaceable interchangeable cassette, each straighteningroll segment comprising at least one layer of supporting rollers and atleast one associated straightening roll. The respective straighteningroll segments therefore form modular segments which each realize a toolmodule, the upper and/or the lower bearing frame providing the toolcarrier. It is consequently possible to configure the upper and/or thelower bearing frame with a variable number of modular straightening rollsegments or tool modules so as to be interchangeable and replaceable,each of which consist of straightening roll and supporting rollercombinations with different diameters, divisions and roll materials andeach of which are selected for the optimum adaptation to thestraightening job to be carried out in each case, in particular thematerial to be straightened in each case. It is possible to replace onlyindividual modular straightening roll segments or, however, also allstraightening roll segments of a bearing frame and, as a result, toretrofit the straightening machine in a corresponding manner.

On account of the modular design, it is additionally possible to realizea large variety of different straightening roll segment combinations inone straightening machine and, as a result, to create clearly improvedadaptability of the straightening machine to different straighteningrequirements and straightening ranges. In this connection, as a resultof selecting the respective straightening roll segments suitably withrespect to the related selection of the grading of straightening rolldiameters and of the division realized therewith, it is also possible toexpand the entire straightening range of the straightening machine in asignificant manner. It is also possible, by means of skillful selectionof the straightening rolls actively participating in the straighteningprocess, to fit out a straightening machine so that it is adapted to therespectively desired technological requirements of the straighteningprocesses and, as a result, to improve the straightening quality. Incases where simply one straightening roll of the equipment of astraightening machine is worn, it is also possible for only the modulewhich comprises said straightening roll to be replaced. It is no longernecessary then to replace the complete set of the straightening machinewhich includes all the straightening rolls.

The fitting out of a straightening machine can, consequently, beeffected in dependence on the metal sheet parameters and tool loadhistory, i.e. on the straightening roll load history. Individualstraightening rolls of a straightening machine are stressed to varyingdegrees during the straightening process such that the operating servicelives thereof are different. The particularly heavily stressed tool canthen be replaced here. However, within the framework of a replacementroutine, a cyclical exchange of different, identically designed modulesis able to be performed at a certain position inside the upper and/orlower bearing frame of the straightening machine.

A further advantage of the invention consists in that now just smallerunits, also from a weight point of view, will have to be replaced in astraightening machine. This makes it possible to work with cranecapacities which have a smaller carrying capacity than those which wouldbe necessary should a complete set of a straightening machine have hadto be replaced as a whole. The necessary space required for one singlemodule-like straightening roll segment is also less than for a completeset of straightening rolls. The lighter weight and the smaller dimensionof a module-like straightening roll segment in relation to a completeset of straightening rolls and/or supporting rollers also makes itpossible then additionally to set up tool centers or processing centers,where applicable, in the vicinity of the straightening machine.

The following advantages can be obtained overall with the invention:

-   -   reduction in the transport weights and in the dimensions of the        tool modules;    -   optimum configuration of the straightening tool with respect to        the product to be straightened;    -   expandable straightening roll/supporting roller combinations        which are adaptable to changes in the production program which        is to be processed with the straightening machine;    -   reduction in the investment costs of a cassette solution        compared to replacing complete sets;    -   reduction in fitting times as a result of the modular design of        the straightening/supporting roller units;    -   as a result of the cyclical replacement of        straightening/supporting roller units inside the cassette, the        service life/lifetime of the tools is able to be standardized.

In one configuration, the invention provides that the straightening rollsegments, which are coordinated with one another in a modular manner,are realized so as to be replaceable individually or in groups and arearranged in the upper and/or the lower bearing frame. The achievementhere is that total, almost complete flexibility with regard to thepositioning of individual straightening roll segments is ensured.

In order to be able to provide the straightening machine withstraightening rolls at different positions in a particularly flexibleand interchangeable manner, it is advantageous according to a furtherdevelopment of the invention when both all the straightening rolls andsupporting rollers which are arranged in the upper bearing frame and allthe straightening rolls and supporting rollers which are arranged in thelower bearing frame are arranged in multiple straightening roll segmentswhich are each coordinated with one another in a modular manner and arerealized in the manner of a replaceable interchangeable cassette.

In order to be able to provide good adaptation to differentstraightening requirements and straightening regions, it is additionallyexpedient for all the straightening rolls and supporting rollers, whichare arranged respectively in the upper and/or lower bearing frame, to bedivided into identical or variously dimensioned types of modularstraightening roll segments and/or interchangeable cassettes, which isalso provided by the invention.

It is additionally expedient to use different types of modularstraightening roll segments such that the invention additionallyprovides that all the straightening rolls and supporting rollers, whichare arranged respectively in the upper and/or lower bearing frame, aredivided, with reference to the respective straightening roll diameterand/or supporting roller diameter and/or with reference to therespective number of straightening rolls and/or of supporting rollers,into types of modular straightening roll segments and/or interchangeablecassettes which are fitted variously with straightening rolls and/orsupporting rollers.

It is particularly advantageous when the individual modularstraightening roll segments each realize an interchangeable cassette andare in each case coordinated with one another such that, as a whole,they realize an interchangeable cassette system which is formed frominterchangeable cassettes which can be exchanged for one another. Theinvention is consequently distinguished additionally in that theindividual modular straightening roll segments realize interchangeablecassettes of an interchangeable cassette system which can be exchangedfor one another individually or in groups.

Such an interchangeable cassette system can include variouslydimensioned types of modular straightening roll segments and/orinterchangeable cassettes, which is also provided by the invention.

In this connection, the interchangeable cassette system can includetypes of modular straightening roll segments and/or interchangeablecassettes which are fitted variously with straightening rolls and/orsupporting rollers with reference to the respective straightening rolldiameter and/or supporting roller diameter and/or with reference to therespective number of straightening rolls and/or of supporting rollers,as a result of which the invention is additionally distinguished.

In order to be able to detect operating data and wear states and to beable to determine and identify service lives and necessary cycles forinterchanging straightening rolls, the invention also provides finallythat said straightening machine comprises means for detecting and/orstoring material parameters of the material to be straightened and/ormeans for detecting and/or storing method parameters which act on eachand every modular straightening roll segment during a straighteningoperation and/or status parameters which are automatically adjusted oneach and every modular straightening roll segment after a straighteningoperation.

The straightening roll segments, which are coordinated with one anotherin a modular manner, are in each case replaceable, complex elements ofthe straightening machine which each form per se a closed operating unitand in this respect a “modular straightening roll segment”.

The invention is explained in more detail below as an example by way ofthe drawing, in which:

FIG. 1 shows a schematic side view of the design of a straighteningmachine according to the invention produced from modular straighteningroll segments,

FIG. 1a shows a schematic side view of a modular straightening rollsegment when seen in side view in the processing direction of thestraightening machine,

FIG. 2 shows exemplary embodiments of possible tool retrofits as aresult of replacing modular straightening roll segments,

FIG. 3 shows a schematic representation of various arrangements ofdifferent combinations of straightening roll segments in the lowerbearing frame,

FIG. 4 shows a schematic representation of various combinations ofmodular straightening roll segments in the upper bearing frame,

FIG. 5 shows a flow chart for detecting and using identified methodparameters and/or status parameters and

FIG. 6 shows a schematic representation of the arrangement of astraightening machine according to the invention with an associated toolprocessing station.

FIG. 1 shows a straightening machine which is designated overall by thereference 1 and includes an upper bearing frame 2 and a lower bearingframe 3. Three straightening roll segments 4, 5 and 6, which arecoordinated with one another in a modular manner, are each realized inthe manner of a replaceable interchangeable cassette and between whichall the straightening rolls 7 and supporting rollers 8 which arearranged in the upper bearing frame 2 are divided, are arranged in theupper bearing frame 2. The three modular straightening roll segments 4,5, 6 are realized uniformly in this exemplary embodiment and eachcomprise both the same number of straightening rolls 7 and supportingrollers 8 and such with identical diameters. The straightening roll 2′is arranged in the modular straightening roll 4, the straightening roll4′ is arranged in the modular straightening roll 5 and the straighteningroll 6′ is arranged in the modular straightening roll 6.

Four straightening roll segments 9, 10, 11 and 12, which are coordinatedwith one another in a modular manner and are each realized in the mannerof a replaceable interchangeable cassette, are arranged in the lowerbearing frame 3. All the straightening rolls 7 and supporting rollers 8arranged in the lower bearing frame 3 are once again divided betweensaid straightening roll segments. In this case too, the straighteningrolls 7 of the respective modular straightening roll segments 9-12comprise the same diameter and are realized with the identical number ina respective modular straightening roll segment 9-12. In the same way,the modular straightening roll segments 9-12 are fitted with supportingrollers 8, each with identical diameters and with the identical number.If a changeover with reference to individual or multiple straighteningrolls 7 and supporting rollers 8 is then to be effected, the individualmodules 4-6 and 9-12 are able to be replaced and interchangedindependently of one another. As a result, the straightening machine 1is able to be adapted to different straightening requirements.

FIG. 1a shows a schematic side view of a modular lower straighteningroll segment 9 when viewed in a side view in the processing direction40. It can be seen how each straightening roll 7 is supported bymultiple supporting rollers 8.

FIG. 2 shows a lower bearing frame 3 where the modular straighteningroll segments 10 and 11 according to the exemplary embodiment accordingto FIG. 1 have been replaced by four straightening roll segments 13-16which are half as wide. The modular straightening roll segments 13-16are also designed identically to one another, but clearly comprisesmaller roller diameters and roll diameters compared to thestraightening roll segments 9 and 12.

In the left-hand part of FIG. 2, it is shown by the dot dash line thatindividual modules, here as an example the modules 12 and 15, can bereplaced within the framework of a tool retrofit. However, it is alsopossible for multiple straightening roll segments to be replaced ingroups, as is shown in the middle image of FIG. 2 in the dot-dashrepresentation. The removed straightening roll segments 13-16 arereplaced by straightening roll segments 17-19 which are to be installed.The right-hand part of FIG. 2 shows a cyclical changing of individualmodular straightening roll segments 13-16. Here, the straightening rollsegment 13 is removed, the straightening roll segments 14-16 then slipto the straightening roll segment 9 in the lower bearing frame 3 toclose the gap created by the removed straightening roll segment 13. Thestraightening roll segment 13 is then inserted, in turn, into the gapcreated on the side of the straightening roll segment 12. In this way,the individual straightening roll segments 13-16 can be moved topositions which are exposed to different mechanical stresses during thestraightening a sheet metal material that is guided by the straighteningmachine.

As a result, uniform wear can be achieved on the straightening rolls ofthe straightening roll segments 13-16.

FIG. 3 shows multiple combination options of various modularstraightening roll segments 9-21 in their arrangement in the lowerbearing frame 3. In an analogous manner, FIG. 4 shows a schematicrepresentation of different arrangements and combinations of modularstraightening roll segments 4-6 and 22-30 in the upper bearing frame 2.

It can be seen from FIGS. 3 and 4 that not only can variously sizedrollers and/or rolls be combined in an arbitrary manner, but also thedivisions (distance between centers) are variable in dependence on thepairing.

In a manner not shown, the individual straightening roll segments canalso be moved vertically up or down, with reference to the sheet metalmaterial traversing the straightening machine, by such an amount thatthey are not continuously in contact with the sheet metal material to beprocessed, as is known, in principle, from sheet metal forming by meansof straightening machines. In this respect, the number of straighteningrolls 7 that are active in each case is able to vary without individualmodular straightening roll segments having to be replaced.

FIG. 5 shows schematically how the processing of the detected statusparameter “straightening roll—actual diameter” and the detected methodparameter “sheet metal data acquisition: temperature, strength,thickness” can be utilized in order, by means of filed data and acomputer and a storage unit, to obtain automated support and indicationas to whether, on the one hand, the correct tool combination, i.e. thecombination of modular straightening roll segments that is necessary inthe current case for achieving the desired straightening result, is setand present and whether they still comprise the necessary statusparameters, i.e. for example, a sufficient straightening roll diameter.This is then checked prior to the start of the sheet metal straighteningprocess, and in the case where the present combination of modularstraightening roll segments is ascertained as not sufficient orapplicable, a tool change or a replacement of individual modularstraightening roll segments is performed. The sheet metal straighteningprocess cannot start until this has been effected.

FIG. 6 shows a schematic representation of the arrangement of astraightening machine 1 according to the invention with an associatedstraightening roll drive 31, which includes a main drive 32 and a masterdrive 33 as well as drive trains 34. A tool processing station 35, whichincludes a grinding machine 36, a reserve of modular straightening rollsegments with straightening roll sets 37 and a tool manufacturing unitwith a crane track 38, is arranged on the side located opposite thestraightening roll drive 31.

The modular straightening roll segments 4-6 and 9-30, with reference tothe frame width 41 of the lower bearing frame 3 or to the frame width 42of the upper bearing frame 2, measured in the processing direction 40 ofa metal sheet to be processed, are coordinated with one another in amodular manner, in dependence on their operation site in the upperbearing frame 2 or in the lower bearing frame 3 with reference to theirrespective width 43, 44, in such a manner that in each case a modularstraightening roll segment or multiple modular straightening rollsegments are able to be placed at a position which is defined by therespective width 43, 44 or by a multiple of a respective width 43, 44.In this connection, it is naturally also possible for the case where acertain position is to be left free, to insert corresponding blocksthere which are not fitted with straightening rolls 7.

LIST OF REFERENCES

1 Straightening machine

2 Bearing frame

3 Bearing frame

4-6 Straightening roll segment

7 Straightening roll

8 Supporting roller

9-30 Straightening roll segment

31 Straightening roll drive

1-9. (canceled)
 10. A straightening machine having an associatedstraightening roll drive, comprising: an upper bearing frame; a lowerbearing frame; and a plurality of straightening rolls and supportingrollers held in the upper bearing frame and the lower bearing frame in acassette-like manner and arranged so as to be replaceable, wherein allthe straightening rolls and supporting rollers, which are arrangedrespectively in the upper and/or lower bearing frame, are divided intomultiple straightening roll segments, which are coordinated with oneanother in a modular manner and are realized in each case as areplaceable interchangeable cassette, wherein each straightening rollsegment includes at least one layer of supporting rollers and at leastone associated straightening roil,
 11. The straightening machineaccording to claim 10, wherein the straightening roil segments, whichare coordinated with one another in a modular manner, are configured soas to be replaceable individually or in groups and are arranged in theupper bearing frame and/or the lower bearing frame.
 12. Thestraightening machine according to claim 10, wherein ail thestraightening rolls and all the supporting rollers arranged in the upperbearing frame and all the straightening rolls and all the supportingrollers arranged in the lower bearing frame are arranged in multiplestraightening roll segments that are each coordinated with one anotherin a modular manner and are configured as a replaceable interchangeablecassette.
 13. The straightening machine according to claim 10, whereinall the straightening rolls and the supporting rollers, which arearranged respectively in the upper bearing frame and/or the lowerbearing frame, are divided into identical or variously dimensioned typesof modular straightening roll segments and/or replacement cassettes. 14.The straightening machine according to claim 10, wherein all thestraightening rolls and the supporting rollers, which are arrangedrespectively in the upper bearing frame and/or the lower bearing frame,are divided, with reference to a respective straightening roll diameterand/or supporting roller diameter and/or with reference to a respectivenumber of straightening rolls and/or number of supporting rollers, intotypes of modular straightening roll segments and/or interchangeablecassettes which are fitted variously with straightening rolls and/orsupporting rollers.
 15. The straightening machine according to claim 10,wherein the individual modular straightening roll segments forminterchangeable cassettes of an interchangeable cassette system that arereplaceable for one another individually or in groups.
 16. Thestraightening machine according to claim 15, wherein the interchangeablecassette system includes variously dimensioned types of modularstraightening roll segments and/or interchangeable cassettes.
 17. Thestraightening machine according to claim 15, wherein the interchangeablecassette system includes types of modular straightening roll segmentsand/or interchangeable cassettes that are fitted variously withstraightening rolls and/or supporting rollers with reference to arespective straightening roll diameter and/or supporting roller diameterand/or with reference to a respective number of straightening rollsand/or number of supporting rollers,
 18. The straightening machineaccording to claim 10, further comprising at least one of: means fordetecting and/or storing material parameters of a material to bestraightened; and means for detecting and/or storing method parameterswhich act on each and every modular straightening roll segment during astraightening operation and/or status parameters which are automaticallyadjusted on each and every modular straightening roll segment after astraightening operation.